The Art of Handcrafting Custom Game Calls > Handcrafting Traditional Reelfoot Duck Calls

Reamers

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Ryan@roosagamecalls:
What type of tapered reamer are you guys using for your real foot calls I've been tapering mine on the lathe but would like to become more precise for a better fit. Thanks

FDR:
I just concluded a personal study on how the old timers did the taper Ryan and came to the conclusion that a Windsor chair reamer is the most likely reamer used.  The most common angle (taper) is 6 to 7 degrees relative to the center line of the insert.
I personally use an old reamer that I found in a tool box but the Windsor chair reamers are available from "Lee Valley" at a very reasonable price.  There are 2 sizes available and you want the larger size.  7  and 9 degree reamers are also available from auto tool suppliers and are used as tie rod end bearing reamers but they run about $100 or more. A much nicer reamer but the price! There are also "Irwin" brand  "handy man" reamers available on Amazon that, in the larger size, will also work and they are under $50. I also use the smaller size Irwin to smooth the inside of the insert and bell the mouth.
I use a guide I made from delrin to align the reamer with the 3/4 hole in the call barrel. I just slip the delrin guide over the reamer tip and insert the reamer/guide in the barrel and turn by hand.

Fred

Ryan@roosagamecalls:
Thank you Fred for goin above and beyond on your answer to my post . I looked up the reamer you mentioned in your tutorial from McMaster Carr . an I'm collecting info to better my reelfoot calls . thank you sir

FDR:
I forgot to mention Ryan that it is also possible to make your own reamer.
My thanks to Marvin H  for these links to "how too" articles.
http://www.greenwoodworking.com/SawSteelTaperedReamerPlans
http://www.finewoodworking.com/how-to/video/how-to-ream-windsor-chair-mortises.aspx
http://lumberjocks.com/mafe/blog/28109

Fred

Ryan@roosagamecalls:
This is the reamer I came up with after doing more research and the valuable information from Fred and Marvin. I added a  3/4 straight end to the reamer to keep every thing in line and its a 6 degree angle which from what I've read is about the strongest angled tennon for chair building. I've made a few practice inserts with it and it holds very well. Thanks for everyones help.

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